Deepwater drilling often requires simultaneously hole-enlargement-while-drilling (HEWD) to improve project economics and preserve hole size for reaching deep reservoirs. The challenge of having two active cutting structures (drill bit and expandable underreamer) in one BHA is improving ROP performance of entire drilling system while preventing premature failure of the underreamer, which is susceptible to vibration induced damages. From an operational standpoint, one potentially disastrous scenario is when underreamer has been severely damaged, but the drill bit is still in good condition. If such situation is not detected promptly and drilling continues, HEWD operation could potentially create a significantly undergauge hole section whose diameter is similar to drill bit. Such consequence can cause enormous difficulty for running/cementing the casing string, and often result in costly remedial operations, or in severe cases, hole abandonment.
To mitigate this risk, an advanced data analytics method was developed to early detect the failure of underreamer by utilizing the standard drilling mechanics data from both surface and downhole sensors. This patent-pending method includes the development of new performance metrics for underreamers based on rock cutting physics and cutter wearing mechanism. This new technology enables the operator to extract insights from similar tool failures in historical data and puts those insights into action on real-time data "in motion". A warning flag can be displayed immediately when the underlying failure pattern is detected by the new method. All relevant rig and office personnel are notified in real-time to promote timely discussion and facilitate decision making.
The operator working in Gulf of Mexico required hole-enlargement-while-drilling to open a pilot hole from 16.5″ to 20″ from 14,000′ MD to approximately 21,000′ MD. The new technology was utilized to monitor the underreamer performance in real-time for this challenging section. The technology provided a warning signal as soon as the algorithm detected the onset of a failure pattern from the underreamer at about the midpoint of the section. When it was pulled to surface, underreamer showed significant damage on cutting structure and had started becoming undergauge. This case study demonstrated the validity of this new method in detecting underreamer failure in real-time. Since then, this technology has been deployed on more than 10deepwaterwells to mitigate the risk of underreamer failure.